Paperboard CD or DVD tray with paper hub

ABSTRACT

A CD or DVD tray made from paperboard is provided. The tray may be made from 100% recycled paperboard and can be 100% recyclable. The design of the tray or holder (used interchangeably throughout) uses the structural geometry of facets, central hole and radial slits to form a hub that achieves the function of securing the CD to the tray. Non-structural paper stock is formed into an effective fastening device whereby the fit of the hub is determined by the geometry of the folded paper. The paper tray of the present invention duplicates the functionality of plastic trays and is compatible with industry auto-loading, while providing the environmental benefits of paper.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Patent Application No. 60/903,747, filed Feb. 27, 2007, the entirety of which is hereby incorporated by reference into this application.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to holders for CD's and DVD's or other digital media. More particularly, the invention relates to CD and DVD trays or holders made of paperboard.

2. Description of Related Art

While there are numerous holder designs being used in the mass production and distribution of CD's, the vast majority are made entirely or contain significant components molded from plastic. Although designs for CD and DVD holders made from paper are known, all have significant drawbacks that prevent their commercial viability. For example, most designs are in the form of a slip case that cannot be used in the auto-loading equipment that the digital music industry currently uses to load recorded CD's onto plastic trays.

U.S. Pat. No. 6,375,003 discloses a paper based holder. The mounting hub, however, is described as being “punched out of the same cardboard material as the case and being disposed on an inside face of the case, the fastening element further having a substantially round and flat structure with the outside diameter thereof being matched to the inside diameter of the centrally disposed hole of the compact disk.”

It would be desirable and environmentally beneficial to provide a CD tray made entirely of paper that duplicates the functionality of plastic and allows industry auto-loading while providing the environmental benefits of paper. It would also be desirable to provide a 100% recyclable paper tray for CDs and DVDs and other discs.

SUMMARY OF THE INVENTION

A CD or DVD tray or cover made from paperboard is provided. The tray may be made from 100% recycled paperboard and can be 100% recyclable. The design of the tray or holder (used interchangeably throughout) in one embodiment uses the structural geometry of folded facets or laminated facets to achieve its function. The paper tray of the present invention duplicates the functionality of plastic trays and is compatible with industry auto-loading, while providing the environmental benefits of paper.

Non-structural paper stock is formed into an effective fastening device whereby the fit of the post or hub (used interchangeably throughout) is determined by the geometry of the folded paper. Prior art plastic CD holders are strong, rigid, often clear, and typically inexpensive to manufacture. However, plastic CD cases are not durable. Even slight impacts can break the plastic tray. The paper tray of the present invention has improved durability over plastic trays and can have graphics printed directly on it. Additionally, paper trays are relatively inexpensive to manufacture.

In a preferred embodiment, a central hole in the formed hub causes the adjacent paper to form a protruding shallow cone which provides a tactile target for positioning the hole in the disc. The hub that is formed has a number of facets which are determined by the number of radial slits on the paper rosette. In the preferred embodiment, the engineering of the center post or hub is designed to enable high volume mass production using conventional paper fabricating equipment. Rather than relying on the “elastic” properties of a punched cardboard hub cited in U.S. Pat. No 6,375,003, this aspect of the invention uses the structural geometry of the facets, central hole and radial slits to achieve its function.

The invention will be more fully described by reference to the following drawings.

DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates four tray styles which may be utilized in accordance with the present invention.

FIG. 2 illustrates the tray construction for the plain tray style.

FIG. 3 illustrates the tray construction for the Jewel case tray style.

FIG. 4 illustrates the formation of a hub which may be utilized in accordance with the present invention.

FIG. 5 illustrates the integration of a hub and tray of one embodiment of the present invention.

FIG. 6 illustrates one embodiment of the production components for the manufacture of a hub.

FIG. 7 illustrates a hub pattern punched into paper stock.

FIG. 8 illustrates a form assembly traveling downward towards hub pattern.

FIG. 9 illustrates the pin of the mandrel engaging the center hole of a punched hub pattern.

FIG. 10 illustrates a perimeter die cutting a hub and releasing it from the hub stock.

FIG. 11 illustrates a mandrel pushing the hub into the pass-thru hole in the upper plate.

FIG. 12 illustrates the mandrel carrying the hub down through the pass-thru hole towards a forming die in lower plate.

FIG. 13 illustrates pre-punched card stock advanced to align hub locator holes with the forming die.

FIG. 14 illustrates hub locator holes in the card stock centered over the forming die.

FIG. 15 illustrates mandrel pushing the hub into the forming die

FIG. 16 illustrates hub being pushed in further the forming die

FIG. 17 illustrates the mandrel carrying hub to the bottom of the forming die.

FIG. 18 illustrates a follower traveling downward towards the formed hub.

FIG. 19 illustrates the follower contacting the facets of the rosette pressing them against exposed adhesive and securing them.

FIG. 20 illustrates the assembly retracting from the formed hub from the die.

FIG. 21 illustrates the assembly clearing upper plate and the hub stock and the card stock advancing.

FIGS. 22A and B show a top and side view of an example of a biodegradable hub 150.

FIG. 23 illustrates an embodiment of a biodegradable hub attached to a tray by heat staking.

DETAILED DESCRIPTION

Reference will now be made in greater detail to a preferred embodiment of the invention, an example of which is illustrated in the accompanying drawings. Wherever possible, the same reference numerals will be used throughout the drawings and the description to refer to the same or like parts.

A preferred embodiment has two components: a tray 10 and a post 50 (or interchangeably referred to as a hub). The hub 50 protrudes from the surface of the tray 10 on the side of the tray 10 that will secure the disc (not shown) CD, DVD or other similar flat circular object with a circular aperture in the approximate center of the object (hereinafter reference to a CD or disc includes CDs, DVDs, digital CDs and any other flat circular object that is to be secured by the tray). The hub 50 can be integral with the tray 10, or alternatively, the hub 50 can be a separate component that is attached or adhered to the tray 10. The tray serves to protect the CD from being scratched or damaged during loading, shipping or handling.

The tray 10 is a flat, typically square or rectangular piece of biodegradable material, such as, for example paper or biodegradable plastic. The shape and dimensions of the tray 10 are not critically important and are preferably compatible with trays currently used in the industry for packaging CDs and DVDs. The dimensions however can be changed to accommodate discs of different sizes. The tray 10 is preferably a die cut piece of paperboard that is folded or laminated or formed into a tray with a circular well 12 that can accommodate a CD. The tray 10 does not have to be die cut or laminated but can be manipulated in any number of ways know in the art such as thermoformed or pressure formed. A circular well 12, however, is not required for the tray to function. In an alternate embodiment the tray is manufactured using paperboard and additional cutouts are laminated onto the paperboard to create the well 12. In another embodiment, the circular well is formed from protruding ridges on the surface of the tray to define a well 12. In yet another embodiment the tray has no circular well 12.

Optionally, the tray can be affixed inside a folded (preferably paperboard) jacket or cover to complete the product package. However, the tray can function to secure the CD or DVD without being incorporated into a jacket or cover.

FIG. 1 illustrates five possible designs 10A-10E for the tray 10. Plain design 10A, two finger cut-outs 10B, four finger cut-outs 10C, jewel case style 10D, and a tray having no well 12 (not shown) are all examples of possible designs for the tray 10. In an alternate embodiment, the circular well is defined by protruding ridges as illustrated in 10E. Other tray designs may be used and the present invention is not limited to any one type of tray design. In one embodiment, the trays are used singly. In another embodiment the trays are used in back-to-back configurations where two or more CD's are to be packaged. The tray configurations are not limited to these embodiments and may be used in any way conventional plastic trays are used to package and store CDs and DVDs.

FIG. 2 illustrates the steps for preparing one embodiment of the tray 10 (plain tray 10A) of the invention with a circular well 12. A piece of paperboard 1 is die cut into a rectangular shape. Two outer folds 2 and 2′ are made and two inner folds 3 and 3′ are made. The paperboard is folded inward at the outer folds 2 and 2′ creating flaps. 4 and 4′. An arc 5 is cut into the flaps 4 and 4′. The flaps 4 and 4′ are then folded inward at the inner folds 3 and 3′ thereby forming the circular well 12. To complete the tray, a center hub 50 is secured at the approximate center of the circular well 12. To construct a tray without a well, the paperboard 1 is simply cut at the position of the inner folds 3 and 3′.

FIG. 3 illustrates the steps for preparing another embodiment of the tray 10 (jewel case style 10D) of the invention with a circular well 12. A piece of paperboard 1 is die cut into a t-shape. Three outer folds 2, 2′ and 2″ are made and three inner folds are made 3, 3′ and 3″. The paperboard is folded inward at the outer folds 2, 2′ and 2″ creating flaps 4, 4′ and 4″. An arc 5 is cut into the flaps 4, 4′ and 4″. The flaps 4, 4′ and 4″ are then folded inward at the inner folds 3, 3′ and 3″ thereby forming the circular well 12. In this embodiment, the center hub 50 is secured at the approximate center of the circular well 12.

The center hub or hub 50 is a three dimensional, preferably paper, structure protruding from the surface 11 of the tray 10. The center hub 50 functions to releasably secure the CD (not shown) to the tray 10.

FIG. 4 illustrates one embodiment of the formation of a hub 50. The hub 50 is formed from a cut paper rosette 40. The rosette 40 contains a small central 42 hole and a plurality of radial slits 44. The radial slits 44 terminate prior to reaching the central hole 42, thereby forming a plurality of facets 48. FIG. 4A and B illustrate different perspectives of the paper rosette 40. As shown in FIGS. 4C-4F, the rosette is folded in a circular pattern at separate positions 43 and 45 along the radius of the rosette 40. The first fold 43 is made between the end of the radial slits 44 and the central hole 42. The second fold 45 is made at a point along the radial slits 44, thereby creating a side wall 46 for the hub 50. When folded in this manner, the hub 50 is hollow and minute points or ridges occur at the outer circumference between the facets 48 which effectively create a hub with a compressible circumference. The paper material being forced into a substantially circular form exhibits increased rigidity at the perimeter of the top of the hub, with less rigidity at the side walls 46 of the hub 50.

The slits 44 in the side wall 46 and central hole 42 of the hub 50 create the ridges that allow for compression of the hub when a CD is pressed onto the hub 50. The ridges of the hub or “retaining ridges” generally define a circular shape that corresponds to that of the hole in the disc to be secured to the tray. The outer circumference of the retaining ridges in the relaxed (non-compressed) state will generally be slightly larger than that of the hole of the disc. The compression of the ridges created by pressing the CD onto the hub allows the CD to be slid past the ridges at the top of the post 50 and held onto the lower post, thereby securing the CD to the tray. Once inserted onto the post 50, the CD is held in place due to the slight outward pressure applied to the CD by the compressed hub 50. This geometry of the hub 50 allows the CD or DVD to be attached and removed from the tray as effectively as a plastic tray and hub.

In the example of FIG. 4 there are ten radial slits 44 and therefore ten facets 48. More or less slits however could be utilized. As less slits are used the resulting hub or hub will have less of circular look from the top view. As more slits 44 are used the hub 50 will have more of a circular look. There is a relationship between the thickness of the paper used to make the rosette and the number of facets needed to obtain a functional hub or post. Generally, thicker paper will require less radial slits and thinner paper will require more to obtain the necessary rigidity of the hub.

The top view of this series of folds to form the hub 50 from the paper rosette 40 is illustrated in FIGS. 5A-D. As illustrated in FIG. 5, after being formed, the exposed edges (ends) 55 of the rosette 40 are secured to the backside of the tray 10, preferably with an adhesive.

In addition to paper or paperboard, the hub 50 may be constructed as illustrated in FIGS. 5A-D from alternate materials. Many materials may be manipulated or formed in the same way that the paper is and achieve the same function as the paper hub 50. Non-limiting examples include many types of film substrates such as celluloids, mylars, foils, and hundreds of plastic sheet materials which could be cold formed (like the paper) into a workable hub based on the same approach of manufacture as describe above. Additionally, a hub of a similar faceted design can be formed from pulp either through heat (thermo formable) or pressure to achieve same utility or function.

FIG. 6 illustrates production components for one embodiment of the hub and tray of the invention. A hub pattern punch 55 is used to cut radial slits 44 and central hole 42 (collectively referred to as the hub pattern 49) in hub stock 30. A die assembly 60 is positioned in line after the hub pattern punch 55. The die assembly 60 includes a perimeter cutting die 62 along with a mandrel 64, step 66, pin 68 and follower 70. There is also an upper plate 86 and lower plate 76. The lower plate 76 has a forming die 80 with lifting pins 82 and is positioned directly under a pass-thru hole 84 of the upper plate 86. The die assembly 60 is positioned in line with the forming die 80 and pass through hole 84 of the upper plate 86. Tray stock 1 (also referred to as paper or card stock) is passed between the upper plate 86 and the forming die 80. The tray stock 1 preferably has a hub locator hole 92 with adhesive 94 applied around the hub locator hole 92.

In operation, a hub pattern 49 (radial slits 44 and central hole 42) is punched into tray stock 30 using the hub pattern punch 55, as illustrated in FIG. 7. The hub stock 30 is moved forward so that the newly cut hub pattern 49 is centered over the pass-thru hole 84 (not shown) of the upper plate 86, as illustrated in FIG. 8. The pin 68 of the mandrel 64 engages the center hole 42 of the punched hub pattern 49 was illustrated in FIG. 9. The perimeter cutting die 62 cuts the hub stock 30 in a circular pattern around the hub pattern and then releases it from hub stock 20, thereby forming the rosette 40 (not shown) as illustrated in FIG. 10.

The mandrel 64 pushes the rosette 40 into the pass-thru hole 84 in the upper plate 86, as shown in FIG. 11 and continues to carry the rosette 40 down through the pass-thru hole 84 towards the forming die 80 in lower plate 76, as shown in FIG. 12. A pre-punched tray stock 1 with hub locator holes 92 is advanced on the lower plate 76 to align the hub locator hole 92 with the forming die 80, as illustrated in FIGS. 13 and 14. The hub locator hole 92 in the tray stock 1 is centered over forming die 80. Preferably, adhesive 94 surrounds the hub locator hole 92.

FIGS. 15-17 illustrate the folding of the rosette described in FIGS. 4 and 5. The mandrel 64 pushing the rosette 40 into the forming die 80 and passing it through the hub locator hole 92 in the tray stock 1. As the rosette 40 is pushed into the forming die 80, the facets 48 are flexed upward. As the rosette 40 is pushed in further, the facets 48 continue to collapse inward where they contact the mandrel 64. As the mandrel 64 carries the rosette 40 to the bottom of the forming die 80, the facets 48 contact the step 66 which folds the facets 48 outward and downward.

FIGS. 18 and 19 illustrate the attachment of the newly formed hub 50 to the tray stock 1. The follower 70 then travels downward towards the formed hub 50 and contacts the facets 48 and presses them against the exposed adhesive 94 around the hub locator hole 92, thereby securing the hub 50 to the tray stock 1. The die assembly 60 retracts and the lifter pins 82, not shown) push tray stock 1 upwards releasing the formed hub 50 from the die 62, as illustrated in FIG. 20.

The process is then complete. The assembly clears the upper plate 86. The hub stock 30 and card stock advance both advance and the cycle is repeated, as illustrated in FIG. 21.

The tray stock with the attached hub is then cut to form individual trays. The tray can then be folded if desired as discussed above in reference to FIGS. 1-3.

In an alternate embodiment, the post or hub is constructed of biodegradable plastic, such as for example PSM Bioplastic from telNnovations Inc. FIGS. 22A and B show a top and side view of an example of a biodegradable hub 150 that can be attached to a tray 10 to make a disc holder. The biodegradable hub 150 can be attached to the tray 10 by heat staking, as illustrated in FIG. 23.

In another embodiment, the tray and/or hub are made in part, or entirely, from recycled paper. Preferably, the entire tray, and cover if used is recyclable. In yet another embodiment, the tray is made from paper and the center hub is made from another biodegradable material, or both the tray and the center hub are made from non-paper, non-plastic biodegradable material.

The hub technology of the present invention is not limited to CD trays and can be used in any application where temporary fastening of a planar object—(via a punched or drilled hole) is required, and a secondary fastener or other material is currently being used. There are numerous packaging/display applications where the hub could be utilized allowing the product to be 100% recyclable.

It is to be understood that the above-described embodiments are illustrative of only a few of the many possible specific embodiments, which can represent applications of the principles of the invention. Numerous and varied other arrangements can be readily devised in accordance with these principles by those skilled in the art without departing from the spirit and scope of the invention. 

1. A disc holder comprising: a tray comprised of paperboard; and a hub constructed of biodegradable material protruding from the surface of the tray, wherein the outer circumference of the hub is compressible.
 2. The disc holder of claim 1 wherein the hub is a paper structure.
 3. The disc holder of claim 2 wherein the hub is hollow.
 4. The disc holder of claim 3 wherein the hub has walls that are compressible.
 5. The disc holder of claim 4 wherein the hub is secured to the tray with adhesive.
 6. The disc holder of claim 5 wherein the hub is comprised of a rosette containing a small central hole and a series of radial slits.
 7. The disc holder of claim 6 wherein the rosette has a plurality of facets corresponding to the number of radial slits punched into the paper rosette and wherein the rosette is folded to form a side wall with ridges that occur between the facets.
 8. The disc holder of claim 1 wherein the hub is constructed of biodegradable plastic.
 9. The disc holder of claim 5 wherein the tray and hub are made from recycled material.
 10. A hub for a CD or DVD holder comprising: a three dimensional structure comprised of biodegradable material, wherein the outer circumference of the hub is compressible.
 11. The hub of claim 10 wherein the biodegradable material is paper.
 12. The hub of claim 10 wherein the three dimensional structure is hollow.
 13. The hub of claim 12 wherein the walls of the three dimensional structure are compressible.
 14. The hub of claim 10 wherein the three dimensional structure is comprised of a rosette containing a small central hole and a series of radial slits.
 15. The hub of claim 14 wherein the rosette has a plurality of facets corresponding to the number of radial slits punched into the paper rosette and wherein the rosette is folded to form a side wall with ridges that occur between the facets.
 16. The hub of claim 10 wherein the three dimensional structure is constructed of biodegradable plastic. 